Powertronix Alcor, User Manual

Page 1: ... notice Page 1 of 46 R D USER MANUAL DT0430 E04 POWERTRONIX UNINTERRUPTIBLE POWER SUPPLY User Manual MIZAR 10 15 kVA ALCOR 20 40 kVA Document DT0430 English Ptx Revision Date Issued by Approved by 03 09 02 2010 Riccardo G Andrea G 04 04 03 2010 Riccardo G Andrea G 05 ...

Page 2: ...T STAGE 8 1 3 3 LOGIC AND AUXILIARY CIRCUITS 9 1 3 4 BATTERIES 9 1 3 5 MANUAL BY PASS 9 1 3 6 FRONT PANEL 9 2 INSTALLATION INSTRUCTIONS 10 2 1 GENERAL INFORMATION 10 2 2 RECEPTION ANDIDENTIFICATION 10 2 3 STORAGE 10 2 4 UPS POSITIONING 11 2 5 ROOM SPECIFICATIONS 13 2 6 LAYOUT AND CONNECTION TO THE MAINS 14 2 7 UPS AUXILIARY CONNECTIONS 20 2 7 1 REMOTE COMMUNICATION BOARD 21 2 7 2 REMOTE PANEL Opti...

Page 3: ...CTIONS FORCOMPLETE SHUTDOWNOF THE UPS 39 4 7 INSTRUCTIONSFOR SWITCHING SYSTEM TO MANUAL BY PASSMODE 40 4 8 INSTRUCTIONSFORRETURN FROM MANUAL BY PASSMODE TO NORMAL OPERATION 41 4 9 E P O EMERGENCY POWEROFF STOP 41 4 10 MANAGING THE UPS BATTERY 42 4 11 BATTERY TEST PROGRAMMING 42 5 UPS IN PARALLEL 43 5 1 SYSTEM SET UP 43 6 TROUBLESHOOTING 44 6 1 GENERAL ALARMS 44 6 2 FIRE 45 6 3 FAULTS RELATED TO TH...

Page 4: ...s technical and administrative offices requiring the power source free from voltage and frequency variations 1 1 2 POWER AND AUTONOMY Thanks to its modular design the UPSes are available in two series with rated power from 10kVA to 15kVA Mizar and from 20kVA to 40kVA Alcor These two families have different power sections while batteries and cabinet remain the same Both UPSes can utilize the intern...

Page 5: ...ATTERY CABINET When the autonomy time provided with the basic configuration is not sufficient additional optional battery cabinet can be connected to the UPS The batteries cabinet can contain up to 2 battery blocks of 4 5 5 7 2 9 Ah 1 2 3 TRANSFORMER CABINET If a galvanic isolating transformer is required it can be positioned inside UPS cabinet in the place of the internal batteries in this case a...

Page 6: ... the PC and dedicated software or through a remote panel There are also voltage free contacts available on the terminal board M1 more info at pages 21 22 1 2 5 UPS MANAGEMENT SOFTWARE The UPS MANAGEMENT Generex communication software allows interaction between UPS and PC or the network based on Windows Win NT Novell OS2 Dec and Linux operating systems The software is used to monitor and control pa...

Page 7: ...icators and the sound signalization in the case of alarm conditions more info at page 22 1 2 7 REMOTE E P O PUSH BUTTON The remote E P O push button provides the safe remote way to fast and full disable the unit running in the event of an emergency more info at page 23 1 2 8 REMOTE MANUAL BY PASS The remote Manual By Pass is a security system that allows when closed to connect directly load to the...

Page 8: ...verload the by pass connects immediately the load directly to the mains through a reserve line making possible normal load operation without interruption See fig 1 3 1 1 3 1 UPS BLOCK DIAGRAM 1 3 2 INPUT STAGE POWER MODULE AND OUTPUT STAGE From the input bars the mains are connected via the MAINS INPUT l1 switch to the power module The rectifier regulates the DC voltage to a reference value chargi...

Page 9: ...sired operation like switch on off inverter or shuts off the UPS The auxiliary power supply supplies all the boards and electronic components in the UPS 1 3 4 BATTERIES The battery set provides energy to the system when the input mains is out of the allowed range or not present in all other cases batteries are constantly recharged by the charger module In this way the batteries are always ready fo...

Page 10: ...ng shipping If there is any damage inform the shipper or retailer immediately Check the supplied material against the packing slip The machine has an adhesive identification plate indicating the type power and serial number it is located on the rear side of the unit Fig 2 2 2 3 STORAGE If the system is not going to be installed immediately it must be stored in an environment with adequate protecti...

Page 11: ...es 10 15 390x900x900 70 220 Tab 2 4a ALCOR POWER kVA DIMENSIONS WxDxH mm WEIGHT Kg w o batteries WEIGHT Kg with batteries 20 25 30 40 390x900x900 80 230 Tab 2 4b The weight difference is in the case the batteries are mounted or not in the same UPS cabinet For handling you need to remember that the machine unless special arrangements are made is shipped and thus handled with the batteries inside th...

Page 12: ... external connections Fig 2 4 1 Air cooling grid 2 Communication cards slot Relay SNMP 3 Switches 4 Metal cover Looking at the back the cables input is located in the lower side that it is accessible removing the metal cover Fig 2 4 For the cables connection according to the UPS configuration refer to fig 2 6c d e at pages 17 18 3 1 2 Metal cover ...

Page 13: ...ted P kVA Diss P W 15 750 40 For correct battery ventilation the room must be able to ensure an exchange of air equal or greater than what is shown in table 2 5b Table 2 5b Remember that the average life of the batteries is closely correlated with the operating temperature a temperature of around 20 C is normally recommended when the temperature rises above 20 for each 10 higher the battery life d...

Page 14: ... current type A Switch A is used as external BY PASS Block diagram 2 6 Config 3 in 3 out Config 1 in 1 out Config 3 in 1 out BATTERIEINTERNE I5 BATTERIA I2 INPUTRISERVA I3 BY P ASS I4 USCITA I5 BATTERIA I4 USCITA BATTERIEINTERNE I1 INPUT M AINS I2 INPUTRISERVA I3 BY P ASS BATTERIEINTERNE I3 BY P ASS I2 INPUTRISERVA I1 INPUT M AINS I5 BATTERIA I4 USCITA I1 INPUT M AINS RESERVELINE CARICO RETE PRINC...

Page 15: ... 33 4 30 60 45 5 45 5 40 40 60 60 7 60 7 53 UPS power kVA Mains input Imax A Reserve input Imax A User outputs Imax A Battery discharge current A 10 20 46 46 13 4 15 20 68 68 20 20 60 91 91 27 25 60 114 114 33 4 30 60 137 137 40 40 60 182 182 53 UPS power kVA Mains input Imax A Reserve input Imax A User outputs Imax A Battery discharge current A 10 60 46 46 13 4 15 60 68 68 20 20 180 91 91 27 25 1...

Page 16: ... shown in diagram 2 6b A general mains circuit breaker switch C automatic switch or at least a fuse for the mains B automatic switch or at least a fuse for the reserve network K3 protection contactor against return voltage K1 K2 additional relays on the change over contact coil supply UPS L1 RESERVE L2 RESERVE L3 RESERVE NEUTRAL L1 MAINS L2 MAINS L3 MAINS NEUTRAL A B C L1 L2 L3 NEUT K2 K1 K3 DISTR...

Page 17: ...re open and disconnected make sure that the battery panel switch is open put warning signs on the distribution panel and battery panel to prevent accidental actions Figure 2 6c UPS terminal block in three phase three phase configuration Remove cables to separate input mains from reserve Figure 2 6c GND L1 L2 L3 N L1 L2 L3 N L1 L2 L3 N N GND INPUT INPUT OUTPUT UPS BATTERY MAINS RESERVE use only wit...

Page 18: ...n Remove cables to separate input mains from reserve Figure 2 6e1 UPS terminal block in three phase single phase configuration Figure 2 6e1 Figure 2 6d GND PHASE N PHASE N PHASE N N GND INPUT INPUT OUTPUT UPS BATTERY MAINS RESERVE use only with Separate reserve Remove connection NEUTRAL Barra parall ING RES GND L1 L2 L3 N PHASE N N GND INPUT MAINS OUTPUT MAINS BATTERY REAR UPS REAR UPS ...

Page 19: ...ns voltage and frequency match those indicated on the adhesive plate located on the rear side of the UPS input voltage operating frequency etc make sure that the earth connection of the system fully complies with the requirements of IEC standards or local laws After that install four pole circuit breakers upstream and downstream from the UPS with the following specifications rating equal or greate...

Page 20: ...IARY CONNECTIONS The communication boards are mounted in the rear UPS section The standard equipment is composed of the remote communication board CS0098 and set up for the SNMP board Access for the connections to these devices is located on the rear part of the UPS fig 2 7a Remote communication board CS0098 SNMP board Fig 2 7a ...

Page 21: ...terminals M1 which can be connected to a dedicated synoptic panel chap 2 7 2 acoustic or visual warning devices or remote signaling systems One or more remote EPO buttons chap 2 7 4 or a remote by pass switch chap 2 7 5 can be connected via the other two contacts CN1 Lastly it is possible to connect the system to a PC via a DB9 CN3 connector and use the specific software chap 2 7 3 Fig 2 7 1a Batt...

Page 22: ...n alarms are present acoustic alarm enabled 2 Yellow ON BATTERY LED If it s on the UPS is operating on battery acoustic alarm enabled 3 Red LOW BATTERY LED If it s on indicates imminent end of battery discharge acoustic alarm enabled 4 Yellow ON BYPASS LED If it s on indicates load supplied from reserve acoustic alarm enabled 5 ALARM SILENCE key Used to switch off the acoustic alarm 6 Green LED If...

Page 23: ...ig 2 7 4 which open the series if commanded generating the stop of the UPS with the consequent and irreversible interruption of voltage to the load The series of external EPO buttons must be connected to the CN1 terminal board of the relay board CS0098 The remote communication card must be configured as described in fig 2 7 4 If there are no external EPO contacts to the system jumper JP1 must be c...

Page 24: ...ircle in fig 2 7 5 The default configuration with any remote by pass connected has the connector CN1 shortened with a wire connection If is required to enable the EPO remote on the optional communication card is necessary contact the service During the feeding of loads through external by pass is not guaranteed the uninterrupted supply of electric current 2 7 6 EARTH CONNECTION The earth input cab...

Page 25: ... which indicates the operating status measurements and alarms of the UPS and the red EPO button located at the left of the display The display panel shows text messages and operating parameters on an LCD screen with 4 lines and 20 characters per line The screens are organized in 6 multi level menus which can be selected using the membrane buttons under the LCD display Two LEDs are present on the l...

Page 26: ...el uses a series of messages to display the operating status of the single component blocks of the system thus the operator is informed in real time also with sound signal of any faults occurred in the system Table 3 1a Figure 3 2 MENU PUSH BUTTON To return to the previous menu or to enter into main menu from the alarm display BACK PUSH BUTTON NEXT PUSH BUTTON To scroll among the menu and the sub ...

Page 27: ...e battery test language EVENTS RECORDER MANAGEMENT 5 Displays the log of events and related alarms SERVICE MODE 6 Reserved for technical assistance service Table 3 2 It is possible to scroll among the listed 6 menu in table 3 2 using the NEXT or BACK keys By pressing the NEXT and BACK keys simultaneously you select ENTER and by confirming the selection go to the next menu level To return to the pr...

Page 28: ... the specified range RESERVE MAINS OK NOT AVAILABLE The input by pass supply line is on and the voltage is is not in the specified range BATTERY FLOAT CHARGE The battery voltage is within the specified limits INVERTER ON The inverter is on and operating normally INVERTER RESERVE SYNCHRONIZED NOT SYNCHRONIZED Indicates the normal synchronization status between the inverter and by pass line LOAD ON ...

Page 29: ...AGE MEANING INVERTER OFF The load is no longer supplied by the inverter and subject to any mains failures INVERTER OVERLOAD The inverter is off due to an overload and the load is supplied by the reserve network STATIC SWITCH LOCKED After 3 unsuccessful automatic switching attempts from the reserve to inverter the UPS blocks the static switch in the reserve network position BATTERY FAILURE BATTERY ...

Page 30: ...he power module input stage output stage and cabinet Temperature temperature of the external battery cabinet in order to regulate the battery voltage according to measured If the operator does not perform any actions for 3 minutes the 1 UPS STATUS AND ALARMS menu is automatically displayed RESERVE NOT AVAILABLE The reserve is not proper for the UPS specifications it might be out of the range allow...

Page 31: ...e numbers 4 2 TIME SETTING Used to set up the actual time using the arrows to increase decrease the numbers 4 3 PANEL LANGUAGE SETTING Used to select the display language available languages 4 4 ALARMS SETUP It allows the user to select the possibility to hide or show a recorded alarm until the ESC button is pushed 4 5 BATTERY TEST SETTING Used to set the periodic battery test selecting the day of...

Page 32: ... menu the user can change UPS rated data reset the EPO reset event log identify the software and hardware version set up the start up of the UPS from normal to automatic and back This menu is password protected to prevent unauthorized access If the operator does not perform any actions for 3 minutes the 1 UPS STATUS AND ALARMS menu is automatically displayed ...

Page 33: ...modify this document without notice Page 33 of 46 R D USER MANUAL DT0430 E04 4 INSTRUCTIONS FOR USING THE UPS IMPORTANT Please carefully follow the below procedures to avoid damages to the system ATTENZION The UPS cannot start from battery ...

Page 34: ... by the UPS The UPS is in normal operation and uses the battery to supply energy to the load because the mains voltage is out of the allowed range This mode guarantees complete uninterrupted power passed to the load 4 2 POWER SWITCHES The system maintenance elements are located behind the front doors installed horizontally and described in order from left to right side refer to the fig 4 3 MAINS I...

Page 35: ... The switches in down position means that the circuit is OPEN The switches in up position means that the circuit is CLOSED The figure 4 3 presents all the switches in OFF position I1 INPUT MAINS I2 INPUT RESERVE I3 MANUAL BY PASS I4 OUTPUT UPS I5 BATTERY I6 NEUTRAL ATTENTION All the operations described below can be executed by authorized electrician or qualified personnel only ...

Page 36: ...ntrol panel _ NORMAL mode optional This mode initiate a start up sequential fully automatic from Precharge to the input stadium to ensure a proper battery charger The manual activation by the operator of the inverter stadium complete the start up procedure at the end you will display the message AUTOSTART PROCESS FINISHED and a green LED switch on on the control panel For proper UPS start up follo...

Page 37: ...atteries close the battery panel switch on battery cabinet It makes the connection between the batteries and the UPS circuits The system makes an automatic battery test 2 minutes after the message AUTOSTART PROCESS FINISHED is shown on the display LCD In case of anomaly an alarm message BATTERY TEST FAILED will be displayed and the red light on the control panel will remain on in this situation ch...

Page 38: ...e start up and call the service 4 Battery connection After checking the correct polarity of the batteries close the battery panel switch on battery cabinet It makes the connection between the batteries and the UPS circuits 5 Switch on the inverter To complete the start up procedure enter into 3 UPS COMMANDS of the menu choose and confirm 3 1 SYSTEM START The inverter will be activated and after 20...

Page 39: ...in the menu 3 UPS COMMANDS and confirm 3 2 SYSTEM STOP Will start an automatic shutdown procedure and on the LCD display will show the percentage of advance At the end will show the 2 message System stop done and on the control panel will be a red LED light From this moment the load is supplied directly from the reserve network 2 Disconnect the battery Open the battery switch on the battery cabine...

Page 40: ... will show percentage of it s advance When the procedure finishes the message System stop done will be displayed and the red indicator will be present on the control panel 4 Close MANUAL BY PASS I3 switch Remove the padlock or any other mechanical safety lock from the switch and lift the knob to ON position The warning sound will be activated and the LCD screen will display Manual bypass switch cl...

Page 41: ...he manual by pass switch l3 On the control panel the red indicator remains on 4 Close the MAINS INPUT l1 switch After few seconds the start up procedure will be started Depending of the UPS start up configuration setting refer to one of the following sections see section 4 4 for AUTOMATIC Start up mode steps 3 4 see section 4 5 for NORMAL Start up mode steps 3 4 5 4 9 E P O EMERGENCY POWER OFF STO...

Page 42: ...ting the menu 3 UPS COMMANDS and pressing ENTER on START BATTERY TEST command The test lasts about 50 seconds It is also possible to schedule a periodic battery test following the instructions below 1 Select the 4 PANEL SETUP menu and press ENTER 2 Select the BATTERY TEST SETTING and press ENTER Select using the arrows the day of the week to perform the test the number of weeks between tests from ...

Page 43: ... of a functional interlocking device is recommended This interlocking device is necessary to prevent damage to the system The indicated solution permits all the testing operations in the installation and maintenance phases of the single groups The general manual by pass can be used to isolate the entire system without load supply interruptions Standardreserve Standardmains Load BATTERIEINTERNE I5 ...

Page 44: ...t not OK Check the battery Check the battery fuses BATTERY PREALARM Battery almost discharged the inverter is about to go off Shut down connected non critical load MAINS NOT AVAILABLE No mains input Check the mains line voltage RESERVE NOT AVAILABLE The input phase rotation is not correct No input voltage Check the line cyclic direction Check the reserve line voltage UPS EMERGENCY POWER OFF The EP...

Page 45: ...are described below The UPS is left with load supplied by the reserve line even if the inverter section is operating correctly this may occur on excessive absorbed peak current It causes the major drop down voltage which if is repetitive leads to the switching load to the reserve line The system after three failed attempts to switch and return to the inverter blocks the static switch on the reserv...

Page 46: ... IN CRITICAL APPLICATIONS The following actions and tests are performed while the scheduled maintenance cleaning the machine cleaning the control logic and interface boards checking the tightening of all nuts and bolts and electrical connections UPS and battery testing the ventilation efficiency testing the inverter output wave form testing output voltage frequency testing synchronization testing ...